2C•1
Chapter 2 Part C:
Engine repair procedures - 1.6 and 1.8 litre 8 valve
Contents
Camshaft - removal, examination and refitting . . . . . . . . . . . . . . . . . 10
Crankshaft and bearings - examination and renovation . . . . . . . . . . 22
Crankshaft and main bearings - refitting . . . . . . . . . . . . . . . . . . . . . . 30
Crankshaft and main bearings - removal . . . . . . . . . . . . . . . . . . . . . 15
Cylinder block/crankcase - examination and renovation . . . . . . . . . 23
Cylinder head - dismantling and overhaul . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cylinder head - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine - adjustments after major overhaul . . . . . . . . . . . . . . . . . . . . 39
Engine - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine ancillary components - removal . . . . . . . . . . . . . . . . . . . . . . 8
Engine ancillary components refitting . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine dismantling - general information . . . . . . . . . . . . . . . . . . . . . 7
Engine reassembly - general information . . . . . . . . . . . . . . . . . . . . . 29
Engine/gearbox - separation and reconnection . . . . . . . . . . . . . . . . 6
Examination and renovation - general information . . . . . . . . . . . . . . 21
Flywheel/driveplate - examination and renovation . . . . . . . . . . . . . . 27
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic bucket tappets - checking free travel (from August 1985) . . 38
Intermediate shaft - examination and renovation . . . . . . . . . . . . . . . 26
Intermediate shaft - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Intermediate shaft - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Major operations only possible after removal of engine from vehicle . . 3
Major operations possible with engine in vehicle . . . . . . . . . . . . . . . 2
Method of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil cooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil filter mounting - removal and refitting . . . . . . . . . . . . . . . . . . . . . 19
Oil pump - examination and renovation . . . . . . . . . . . . . . . . . . . . . . 25
Oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pistons and connecting rods - examination and renovation . . . . . . . 24
Pistons and connecting rods - refitting . . . . . . . . . . . . . . . . . . . . . . . 32
Pistons and connecting rods - removal . . . . . . . . . . . . . . . . . . . . . . . 14
Sump and oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . 13
Timing belt and sprockets - examination and renovation . . . . . . . . . 28
Timing belt and sprockets - refitting . . . . . . . . . . . . . . . . . . . . . . . . . 35
Timing belt and sprockets - removal . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valve clearances - checking and adjustment (pre August 1985) . . . 33
Degrees of difficulty
Easy, suitable for
novice with little
experience
1
Fairly easy, suitable
for beginner with
some experience
2
Fairly difficult,
suitable for competent
DIY mechanic
3
Difficult, suitable for
experienced DIY
mechanic
4
Very difficult,
suitable for expert DIY
or professional
Specifications
General
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code:
1.6 litre:
Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre:
Jetronic - fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GTi - January 1987 on:
Without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement:
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore:
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke:
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio:
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre
Code RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four-cylinder in-line, water cooled, overhead camshaft
EZ
RF
EV
GU
PB, GU
RH, RP, PF
1-3-4-2 (No 1 at camshaft sprocket end)
1595 cc
1781 cc
81.0 mm
81.0 mm
77.4 mm
86.4 mm
9.0 to 1
9.0 to 1
10.0 to 1
1081 VW Golf & Jetta
5
2C
2C•2 Engine repair procedures - 1.6 and 1.8 litre 8 valve
Compression pressure:
1.6 litre:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum permissible difference between any two cylinders . . . .
1.8 litre:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum permissible difference between any two cylinders . . . .
9 to 12 bar
7.5 bar
3.0 bar
10 to 13 bar
7.5 bar
3.0 bar
Crankshaft
Main journal:
Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankpin:
Standard diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Endfloat:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing maximum running clearance . . . . . . . . . . . . . . . . . . . . . .
54.0 mm
53.75, 53.50 and 53.25 mm
47.80 mm
47.55, 47.30 and 47.05 mm
0.25 mm
0.07 mm
0.17 mm
Connecting rods
Big-end:
Maximum running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.012 mm
0.37 mm
Pistons
Clearance in bore:
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oversize:
1st oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear limit (10 mm from base/ right angles to pin) . . . . . . . . . . . . . . . . .
0.07 mm
0.03 mm
80.98 mm
81.23 mm
81.48 mm
0.04 mm
Piston rings
Maximum clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End gap:
Compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil scraper ring:
1 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.15 mm
0.30 to 0.45 mm
0.25 to 0.40 mm
0.25 to 0.45 mm
0.25 to 0.50 mm
1.0 mm
Gudgeon pin
Fit in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Push fit at 60°C
Intermediate shaft
Maximum endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25 mm
Cylinder head
Maximum allowable face distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.1 mm
132.6 mm
Camshaft
Run-out at centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.01 mm
0.15 mm
Valves
Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head diameter:
Inlet:
Codes PB, PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45°
40.0 mm
38.0 mm
33.0 mm
1081 VW Golf & Jetta
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•3
Stem diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.97 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.95 mm
Standard overall length*:
Inlet:
Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.70 mm
All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.0 mm
Exhaust:
Codes EZ, EV, GU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.50 mm
Codes PB, PF, RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.95 mm
All other codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.80 mm
* Caution: Check with manufacturer on valve dimensions before renewing
Valve guides
Maximum valve rock (stem flush with guide):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.0 mm
1.3 mm
Hydraulic tappets
Maximum free travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.1 mm
Valve timing
Nil valve clearance at 1.0 mm valve lift
1.6 litre (code EZ - shim bucket tappets):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 litre (code EZ - hydraulic tappets - August 1985 to March 1986):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 litre (code EZ - hydraulic tappets - March 1986 on):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 litre (code RF):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (code GU - shim bucket tappets)
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (code GU - hydraulic tappets - August 1985 to March 1986
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (code GU - hydraulic tappets - March 1986 on):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (code EV):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (codes PB, PF):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5° BTDC
21° ABDC
41° BBDC
3° BTDC
3° BTDC
19° ABDC
27° BBDC
5° BTDC
TDC
22° ABDC
28° BBDC
6° BTDC
TDC
22° ABDC
28° BBDC
6° BTDC
1° BTDC
37° ABDC
42° BBDC
2° ATDC
3° BTDC
33° ABDC
41° BBDC
5° BTDC
2° BTDC
34° ABDC
44° BBDC
8° BTDC
2° BTDC
45° ABDC
45° BBDC
8° BTDC
3° ATDC
43° ABDC
37° BBDC
3° ATDC
1081 VW Golf & Jetta
2C
2C•4 Engine repair procedures - 1.6 and 1.8 litre 8 valve
Valve timing (continued)
Nil valve clearance at 1.0 mm valve lift
1.8 litre (code RH):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (code RP - pre July 1988):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 litre (code RP - August 1988 on):
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2° BTDC
34° ABDC
44° BBDC
8° BTDC
2° ATDC
38° ABDC
40° BBDC
4° BTDC
5° BTDC
41° ABDC
37° BBDC
1° BTDC
Valve clearances
Warm:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.20 to 0.30 mm
0.40 to 0.50 m
0.15 to 0.25 mm
0.35 to 0.45 mm
Lubrication
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant type/specification/capacity . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure (2000 rpm with oil temperature 80°C) . . . . . . . . . . . . . . . . . . .
Wet sump, pressure feed, full flow filter
Refer to “Lubricants, fluids and capacities”
Champion C101/C160
Twin gear, driven by intermediate shaft together with distributor
2.0 bar minimum
Torque wrench settings
Nm
lbf ft
45
75
25
10
20
100
20
30
65
33
55
18
7
15
74
15
22
48
30
Further tighten 1/4 turn (90°)
10
25
25
22
20
10
25
20
80
10
45
200
80
20
10
30
10
20
20
25
15
7
18
15
59
7
33
148
59
15
7
22
7
15
15
18
Engine to gearbox:
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch pressure plate/washer bolts (renew) . . . . . . . . . . . . . . . . . . . . . .
Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod big-end cap nuts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 2* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seal flange bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate shaft flange bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft bearing cap nuts (in sequence) . . . . . . . . . . . . . . . . . . . . . . .
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt tensioner pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft sprocket bolt (oiled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate shaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear cover lower bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear cover top bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1081 VW Golf & Jetta
7
18
18
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•5
Cylinder head bolts (engine cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As for 1.05 and 1.3 litre engines
Refer to illustration 5.25b. Also 40.1a and 40.1b in Part A of this Chapter.
a) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
18
a) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
33
b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
26
c) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
33
d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
37
e) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
44
f) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
52
g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
59
* When checking the connecting rod-to-crankshaft journal radial clearance using Plastigage, tighten only to 30Nm (22 lbf ft).
1 General information
The 1.6 and 1.8 litre 8-valve engines are of
four-cylinder, in-line, overhead camshaft
design, mounted transversely at the front of
the vehicle. The transmission is attached to
the flywheel end of the engine.
The crankshaft is of five main bearing type,
its endfloat being controlled by a shouldered
centre bearing or by half thrustwashers
located each side of the centre bearing.
The camshaft is driven by a toothed belt
which is tensioned by a tensioner on an
eccentric bearing. On engines manufactured
before August 1985, the valves are operated
by bucket type cam followers in direct contact
with the camshaft. From August 1985, all
engines are fitted with a redesigned cylinder
head incorporating hydraulic bucket tappets
in place of the previous shim bucket tappets.
Camshaft bearing No. 4 is deleted on all
single camshaft engines. In order to identify
the type of tappets fitted, a sticker is normally
affixed to the valve cover indicating that valve
clearance adjustment is neither necessary nor
possible.
An intermediate shaft (driven by the toothed
timing belt) drives the distributor and oil pump
and on carburettor equipped engines, the fuel
pump.
The oil pump is of twin gear type, driven
from the immediate shaft and incorporates a
pressure relief valve.
The aluminium cylinder head is of
conventional design with the inlet and exhaust
manifolds mounted on the rear side (as
viewed with the engine in the vehicle).
The
crankcase
ventilation
system
comprises a hose from the flywheel end of the
valve cover to the side of the air cleaner.
On fuel injection equipped engines, there is
a hose to the air inlet manifold and a hose to
the air cleaner from a three-way connector on
the valve cover.
2 Major operations possible
with engine in vehicle
The following operations can be carried out
without having to remove the engine from the
vehicle:
a) Removal and servicing of the cylinder
head, camshaft and timing belt
b) Renewal of the crankshaft rear oil seal
(after removal of the transmission,
driveplate or clutch as applicable)
c) Removal of the sump and oil pump
d) Removal of the piston/connecting rod
assemblies (after removal of the cylinder
head and sump)
e) Renewal of the crankshaft front oil seal,
intermediate shaft front oil seal and
camshaft front oil seal
f) Renewal of the engine mountings
3 Major operations only
possible after removal of
engine from vehicle
The following operations can only be
carried out after removal of the engine from
the vehicle:
a) Renewal of crankshaft main bearings
b) Removal and refitting of the crankshaft
c) Removal and refitting of the intermediate
shaft
4 Method of engine removal
1 The engine, together with the gearbox,
must be lifted from the engine compartment,
then the engine separated from the gearbox
on the bench. Two people will be needed.
2 A hoist of 150 kg capacity will be needed to
lift the engine approximately 1 metre. If the
hoist is not portable and the engine is lifted,
then sufficient room must be left behind the
vehicle to push it back out of the way so that
the engine may be lowered. Blocks will be
needed to support the engine after removal .
3 Ideally, the vehicle should be over a pit. If
this is not possible then the body must be
supported on axle stands (see “Jacking and
vehicle support”) so that the front wheels may
be turned to undo the driveshaft nuts. The
left-hand shaft is accessible from above but
the right-hand shaft must be undone from
underneath. Removal of the gearshift linkage
can only be done from underneath, as can
exhaust downpipe-to-manifold detachment.
4 The exhaust downpipe-to-manifold flange
connection is secured by special spring clips
rather than bolts or studs and nuts. When
1081 VW Golf & Jetta
disconnecting and reconnecting the joint, it
will be necessary to use VW tool no. 3049A.
Without this tool, detachment and certainly
reconnection of the joint and clips is virtually
impossible, so make arrangements to borrow
or hire the tool in advance.
5 The only other special tools required will be
a set of splined key wrenches which will be
needed to remove and refit the socket-head
bolts used to secure certain items such as the
cylinder head bolts.
6 Draining of oil and coolant is best done
away from the working area if possible. This
saves the mess made by spilled oil in the
place where you must work.
7 Although not listed as an optional fitting on
UK models, an air conditioning system may
have been fitted. Where this is the case, the
following precautions must be taken when
handling refrigerant lines or system
components:
a) Do not stress or bend flexible hose lines
to a radius of less than 101 mm
b) Flexible hose lines must be correctly
located, must not chafe against adjacent
components and must be kept well clear
of the exhaust manifold and downpipe
c) All metal tubing lines must be kept free of
kinks and must be handled with care
d) Do not disconnect any of the air
conditioning supply lines
e) Do not weld or apply heat in the vicinity of
the air conditioning lines or equipment
f) If any part of the system is to be detached
then it must first be depressurised by your
VW dealer or a competent air conditioning
systems engineer. The only exception is
the removal and fitting of the compressor
drivebelt which can be achieved in the
same manner as for the alternator
drivebelt
5 Engine - removal
4
Carburettor equipped
1 Disconnect the battery negative lead.
2 Remove the bonnet.
3 Drain the engine coolant.
4 Position a suitable container beneath the
engine, undo the sump drain plug and drain the
engine oil - see Chapter 1. On completion clean
the drain plug and refit it. Renew the O-ring.
2C
2C•6 Engine repair procedures - 1.6 and 1.8 litre 8 valve
5.8a Oil pressure switch location in rear of
cylinder head
5 Remove the radiator, together with the
cooling fan. On models manufactured after
1986, remove the front panel before removing
the radiator.
6 Remove the air cleaner unit then disconnect
the throttle cable at the carburettor. Position
the cable out of the way.
7 Where power steering is fitted, remove the
hydraulic pump drivebelt. Unbolt the pump,
belt tensioner and fluid reservoir and tie them
to one side of the engine compartment.
8 Disconnect
the
following
wiring
connections, identifying each lead as it is
detached to avoid confusion on reassembly:
a) Alternator lead
b) Oil pressure switch lead(s) at cylinder head
(see illustrations) and oil filter bracket
c) Inlet manifold preheater thermo-switch
lead
d) Choke cover thermo-switch lead (where
applicable)
e) Ignition HT and LT leads
f) Choke cover lead separate connector
g) Coolant temperature sender unit lead
h) Earth strap to gearbox (see illustration)
and multi-function switch to gearbox
i) Starter motor leads
9 Disconnect the fuel supply hose from the
fuel pump and the fuel return hose (to the fuel
tank). Plug the hoses to prevent fuel leakage.
10 Disconnect the coolant and heater hoses
from the engine.
5.8b Oil pressure switch location in filter
mounting
5.8c Earth strap to gearbox
5.24 Engine rear bearer
5.25a Engine/gearbox unit front mounting
11 On manual gearbox models, disconnect
the clutch cable.
12 Disconnect the following items from
around the carburettor. Identify the
connections where necessary to avoid
confusion on reassembly:
a) Thermotime valve
b) Idle/overrun cut-off valve
c) Inlet manifold preheater separator
connector
d) Part throttle channel heater separate
connector
13 Disconnect the speedometer cable from
the transmission.
14 Disconnect and remove the vacuum
reservoir.
15 Disconnect the brake vacuum servo
hoses and the vacuum hoses from the inlet
manifold.
16 Undo and remove the gearbox mounting
bolt.
17 Raise and support the vehicle on axle
stands (see “Jacking and vehicle support”),
allowing sufficient clearance to work
underneath.
18 Disconnect the manual gearbox linkage.
19 On automatic transmission models, select
P (Park) then disconnect the throttle and
selector cables from the transmission.
20 Disconnect the driveshafts from the
gearbox and tie them up out of the way.
21 To disconnect the exhaust manifold to
downpipe connection, VW tool no. 3049A will
be required. Although it may be possible to
prise the clips free to separate this joint, the
tool will definitely be required to refit the
springs.
22 The vehicle can now be lowered, the
remaining removal operations being from
above.
23 Attach a suitable sling and hoist to the
engine/gearbox unit and take its weight.
24 Disconnect the rear engine bearer by
undoing the three bolts (see illustration).
25 The engine/gearbox unit front mounting
must now be detached by unscrewing and
removing the single through-bolt. It may be
necessary to further lift, lower or twist the unit
to allow the through-bolt to be withdrawn (see
illustration). Note that from December 1984,
the front mounting is changed from the
bonded rubber type to a ‘hydro’ type with
damping action (see illustration).
5.25b Hydro-type front engine mounting
Refer to Specifications for fastener torque wrench settings b, e and f
1081 VW Golf & Jetta
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•7
26 The engine/gearbox unit is now ready for
lifting out but first make a final check that all
cables, wiring and hoses are clear.
27 Have an assistant at hand to help guide
the unit clear of the surrounding components
in the engine compartment as it is lifted out.
The unit will have to be twisted slightly as it is
raised. Once clear of the vehicle, lower it to
the work surface.
Fuel injection equipped
28 On fuel injection equipped engines, the
removal procedure closely follows that given
for carburettor equipped engines. However,
disregard those items concerning detachment
of the carburettor and associated items. The
following injection equipment items will need
to be disconnected instead. Refer to Chapter
4 for further details:
29 Disconnect the wires from the warm-up
valve (green connector) (see illustration).
30 Disconnect the wiring to the cold start
valve (blue connector).
31 Disconnect the wiring to the auxiliary air
valve.
32 Disconnect the throttle cable at the fast
idle cam and bracket but do not remove the
securing clip (see illustration).
33 Remove the cold start valve but leave the
fuel lines connected. Place out of the way.
34 Disconnect the air inlet pipe at the flexible
ducting attached to the throttle housing.
35 Disconnect the vacuum hoses from the
inlet manifold and vacuum booster.
36 Leaving the fuel lines connected, undo the
retaining bolts and withdraw the warm-up
valve from the cylinder block. Position out of
the way.
37 Detach the injectors from the cylinder
head and plug the holes. Disconnect the
injector lines from the locating bracket on the
throttle housing and fold them out of the way.
38 Detach the vacuum hoses to the throttle
housing T-piece connector location clip at the
5.29 Wiring connections to be detached - fuel injection models
1 Alternator
2 Warm-up valve
3 1.8 bar oil pressure
switch
4 Oil temperature sender
bulkhead. Fold the hoses back out of the way.
39 Disconnect the oil temperature switch
sender lead (see illustration).
40 When lifting out the engine/gearbox unit,
greater care will have to be taken in
manoeuvring the unit from the engine
5.32 Fuel injection components to be detached
1 Throttle cable
2 Cold start valve
3 Vacuum hoses
4 Air intake pipe
5 Distributor HT cable
(terminal 4)
6 Hall sender (distributor)
7 Vacuum switch
8 Coolant temperature
sender
9 Thermotime switch
10 0.3 bar oil pressure
switch
11 Cold start valve
12 Auxiliary air valve
compartment due to the close proximity of the
air inlet manifold to the bulkhead. The unit will
need to be pulled forwards first then twisted
and lifted.
5.39 Oil temperature sender (arrowed)
5 Injectors
1081 VW Golf & Jetta
2C
2C•8 Engine repair procedures - 1.6 and 1.8 litre 8 valve
6 Engine/gearbox - separation
and reconnection
3
This procedure is fully described in Chapter
7, Parts A or B, as applicable. It is only
necessary to refer to those paragraphs
pertinent to the particular method being used.
The engine must be supported on blocks, or
alternatively the gearbox can be separated
with the engine still on the hoist.
7 Engine dismantling - general
information
Refer to Section 7 in Part A of this Chapter.
8 Engine ancillary components
- removal
3
With the engine removed from the vehicle
and separated from the transmission, the
externally mounted ancillary components can
be removed prior to engine dismantling. The
removal sequence need not necessarily follow
the order given:
a) Alternator and drivebelt
b) Inlet manifold and carburettor or inlet
manifold and throttle housing (fuel
injection)
c) Exhaust manifold
d) Fuel pump
e) Warm-up valve (fuel injection), if still
attached
f) Distributor
g) Oil filter with cooler (where applicable)
and filter mounting
h) Oil pressure and coolant temperature and
sensor switches
I) Coolant pump and coolant hose
connectors from cylinder block and head.
New O-rings will be required
j) Clutch then intermediate plate (manual
gearbox)
k) Driveplate, noting location of spacer and
shim(s) (automatic transmission)
9 Timing belt and sprockets removal
1 If the engine is still in the vehicle, first carry
out the following operations:
a) Disconnect the battery earth lead
b) Remove the alternator drivebelt
c) Unbolt and remove the coolant pump
pulley
2 Depending on type, undo the retaining
bolt(s)/nut(s), release the retaining clips and
remove the upper timing cover (see
illustration). On some engines it will be
necessary to remove the bung from the front
9.2 Timing belt and cover components
1081 VW Golf & Jetta
3
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•9
9.6 Intermediate sprocket timing mark (arrowed) aligned with
notch in crankshaft pulley
face of the cover to allow access to the Allen
type retaining screw recessed within the
cover. On other engines, the retaining screw
can be seen but its key slot is deeply
recessed (access to it being made via the hole
in the centre of the screw surround).
3 Unscrew the nuts and bolts from the valve
cover and remove the cover together with the
gasket and reinforcement strips. Detach the
crankcase emission hose(s) from the rocker
cover.
4 Mark the relative positions of the crankshaft
pulley and crankshaft sprocket, then undo the
four socket-head bolts and withdraw the
pulley.
5 Unbolt and withdraw the lower timing
cover.
6 The engine must now be set for timing.
Temporarily refit the crankshaft pulley. On the
intermediate sprocket for the timing belt one
tooth has a centre-punch mark. Turn the
engine until this mates with a notch on the
V-belt pulley bolted to the crankshaft sprocket
(see illustration). To turn the engine over,
remove the spark plugs then fit a suitable
spanner onto the crankshaft sprocket
retaining bolt and turn it in the direction of
engine rotation.
7 When these marks match, look at the
sprocket on the camshaft. One tooth of this
has a centre-punch mark. This should be level
9.7a Camshaft sprocket timing mark (arrowed) with No 1 cylinder
at TDC on compression
with the valve cover flange (see illustration).
Having turned the engine until these marks
agree, now look at the cams for No 1 cylinder
(nearest the timing belt). They will both be in
the ‘valve closed’ position (see illustration).
Now look through the hole in which the TDC
sensor goes where the timing marks show on
the periphery of the flywheel and note the
reading.
8 Before removing the timing drivebelt, check
its correct tension. If held between the finger
and thumb halfway between the intermediate
shaft and the camshaft it should be just
possible to twist it through 90° (see
illustration). If it is too slack, adjust it by
slackening the bolt holding the eccentric cam
on the tensioner wheel. If you are satisfied it
can be adjusted to the correct tension,
remove it and examine it for wear. Now is the
time to order a new one if necessary.
9 Loosen the tensioner then withdraw the
timing belt from the camshaft, intermediate
and crankshaft sprockets.
10 Each of the timing belt sprockets is
secured by a central bolt and washer. The
intermediate, camshaft and crankshaft
sprocket (the latter in particular) securing
bolts are tightened to a substantial torque and
the sprockets will therefore need to be firmly
held when undoing the bolts.
11 To remove the camshaft sprocket,
unscrew the bolt with the sprocket held
stationary by inserting a suitable metal bar
through a sprocket hole and resting it on the
valve cover face of the cylinder head, but take
care not to damage the face. Remove the bolt
and spacer washer then withdraw the
sprocket, tapping it free if necessary. Check
the fit of the Woodruff key in the camshaft, it
must be renewed if loose in its groove. Lever
out the Woodruff key and keep it with the
sprocket.
12 To remove the crankshaft sprocket, hold
the crankshaft stationary with a lever jammed
in the starter ring gear (remove the starter
motor as applicable). Do not allow the
crankshaft to turn or the pistons may touch
the valve heads. Unscrew the retaining bolt
and remove it, together with the spacer
washer, then lever the sprocket free from the
crankshaft. Check the fit of the Woodruff key
(if fitted) in the crankshaft, it must be renewed
if loose in its groove. Lever out the Woodruff
key and keep it with the crankshaft sprocket.
13 The intermediate shaft sprocket is
removed in a similar manner to that for the
camshaft sprocket.
10 Camshaft - removal,
examination and refitting
3
Removal
9.7b No. 1 cylinder cam lobes in valve
closed position
9.8 Timing belt tension check method
1081 VW Golf & Jetta
1 To remove the camshaft with the engine in
the vehicle, first carry out the following
operations:
a) Remove the timing cover and valve cover,
then disconnect the timing belt from the
camshaft sprocket
2C
2C•10 Engine repair procedures - 1.6 and 1.8 litre 8 valve
b) If the camshaft oil seal is to be renewed
then the camshaft timing sprocket must
be removed
2 Remove the camshaft bearing caps (see
illustrations), making a careful note of their
fitted positions for reference when refitting .
The caps are numbered (see illustration) but
mark the side nearest the front of the cylinder
head. No. 1 cap is the one with a small oil seal
on it.
3 Remove cap nos. 5, 1 and 3 in that order.
Now undo the nuts holding 2 and 4 in a
diagonal pattern. The camshaft will lift the
caps up as the pressure of the valve springs is
exerted. When they are free, lift the caps off
along with the camshaft. The oil seal on the
front end of the camshaft will come with it.
Depending on tappet type, proceed as
follows:
Shim bucket tappets
10.2a Cylinder head and camshaft components - carburettor engine
4 The tappet buckets are now exposed and
may be lifted out (see illustration). Take each
one out in turn, prising the little disc out of the
bucket by inserting a small screwdriver either
side and lifting the disc away. On its reverse,
each disc is engraved with a size (eg. 3.75).
This is its thickness number. Note the number
and then clean the disc and refit it, number
side down. There are eight of these and they
must not be mixed up. On assembly, each
disc must go back into the bore from whence
it came. This problem exists also for the
valves, so a container for each valve assembly
10.2c Camshaft bearing cap number
(arrowed)
10.4 Tappet bucket and shim
10.2b Cylinder head and camshaft components - fuel injection engine
1081 VW Golf & Jetta
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•11
and tappet is required. Label the containers 1
to 8, as follows:
Containers 1 and 2 will be No 1 cylinder
exhaust and inlet respectively
Containers 3 and 4 will be No 2 cylinder
exhaust and inlet respectively
Containers 5 and 6 will be No 3 cylinder
inlet and exhaust respectively
Containers 7 and 8 will be No 4 cylinder
inlet and exhaust respectively
5 Note the thickness of all tappet clearance
discs from Nos. 1 to 8 for use during
reassembly.
Hydraulic bucket tappets
6 Lift out the tappets one by one, ensuring
that they are kept in their correct order and
can be returned to their original bores.
7 Place them, cam contact surface down, on
a clean sheet of paper as they are removed.
8 Inspect the tappets for wear (indicated by
ridging on the clean surface), pitting and
cracks.
9 Tappets cannot be repaired and if worn,
must be renewed.
Examination
10 Refer to Section 27 in Part A of this
Chapter whilst noting that on exchange
engines or cylinder heads, the camshaft is
supplied with bearing shells instead of running
directly in the head and bearing caps.
Exchange units supplied by VW may have an
undersized camshaft with corresponding
bearing shells. Where this is the case, the
camshaft will have a yellow paint spot on it
and the journal diameter will be 25.75 mm. An
unmarked camshaft supplied with bearing
shells will be of standard size with a journal
diameter of 26.00 mm.
Refitting
11 Refer to Section 12.
11 Cylinder head - removal
3
All engines
1 If the cylinder head is being removed with
the engine out of the vehicle, proceed from
paragraph 17. If the cylinder head is being
removed with the engine in the vehicle, it is
best removed with the inlet and exhaust
manifolds. The manifolds can then be
detached after removal of the cylinder head
but note that a special tool is required to
release (and subsequently reconnect) the
exhaust downpipe-to-manifold flange retaining
clips. A splined key will also be required to
undo and tighten the cylinder head bolts.
2 Disconnect the battery earth lead. Drain the
cooling system, then disconnect the cooling
and heater hoses from the cylinder head.
3 Disconnect the thermoswitch and oil
pressure lead connections.
4 On carburettor models, remove the air
cleaner unit.
5 Disconnect the alternator from the cylinder
head attachment brackets and remove the
drivebelt.
6 If removing the manifolds with the cylinder
head, disconnect the vacuum hose from the
inlet manifold and the accelerator cable (and
choke cable if applicable) from the
carburettor.
7 Disconnect the HT leads from the spark
plugs.
Fuel injection equipped engines
8 Detach the injector lines from the cylinder
head and location clips and fold them back
out of the way.
9 Disconnect the inlet duct at the flexible
hose connection to the throttle valve housing.
10 Detach the vacuum hoses to the throttle
valve housing and at the three-way connector
on the bulkhead side of the cylinder head.
Fold back and secure the hoses out of the
way.
11 Disconnect the auxiliary air valve lead
from the underside of the inlet manifold and
the auxiliary air valve hose to the flexible hose
on the throttle valve housing.
12 Disconnect the servo vacuum hose from
the green connector on the flexible hose on
the throttle housing.
13 If air conditioning is fitted, detach the
hoses from the auxiliary air valve and tube
connections.
14 Detach the MFI hose at the servo hose
valve connection.
15 Detach the wiring connector from the cold
start valve.
All engines
16 Remove the timing cover and valve cover,
then disconnect the timing belt from the
camshaft sprocket.
17 Remove the camshaft.
18 Remove the cylinder head bolts. These
are recessed in the well of the cylinder head
and are socket-head bolts. They must be
removed using the correct splined tool.
19 The cylinder head bolts must be
unscrewed in a progressive manner and in the
reverse sequence to that shown for
tightening.
12.2 Improvised tool used to remove and
refit collets to valve stems
1081 VW Golf & Jetta
20 When all ten bolts have been removed, lift
the head from the cylinder block. It may need
a little tapping to loosen it but do not try to
prise it loose by hammering in wedges. Lift off
the gasket and, if the engine is not being
dismantled, clean the piston crowns and
block face. Note that the cylinder head bolts
must not be re-used, a new set will need to be
obtained when ordering the cylinder head
gasket set.
12 Cylinder head - dismantling
and overhaul
3
1 Using a wire brush, scraper and steel wool,
clean all carbon from the combustion
chambers, valve faces and exhaust ports.
Remove the spark plugs for cleaning.
2 The valves are not easy to get out unless a
suitable valve spring compressor is available.
Because the collets and spring caps are set
so far down in the head, a long claw is
necessary on the compressor and it must be
split sufficiently to enable the collets to be
removed and inserted. If such a tool is not to
hand then find a piece of steel tube of about
25 mm inside diameter which will fit over the
valve stem and press down the spring cover
(see illustration). The length will depend on
the size of the compressor so fit the
compressor over the head fully extended,
measure the distance between the claw and
the valve spring seat and cut the tube to a
suitable length.
3 The next step is to cut two windows of
suitable size (approx. 25 mm long and 16 mm
wide) in opposite sides of the tube. The tube
may then be used with the compressor to
extract the collets from each valve stem in
turn. Place the valve, springs, collets and
seats with the tappet in the appropriate
receptacle, keeping them strictly together for
refitting in the valve guide from which they
were taken (see illustration).
If your fingers are too big,
put a blob of grease on the
collet and pick it up with a
small screwdriver, then
insert it into the slot on the valve stem.
12.3 Valve springs, cap and collets
2C
2C•12 Engine repair procedures - 1.6 and 1.8 litre 8 valve
12.12a Inserting a valve into the cylinder
head
12.12b Locating valve springs and cap . . .
12.12c . . . and valve collets
4 The valve springs must be renewed if they
are damaged, distorted, or known to have
covered a high mileage. If in doubt as to their
condition, have your VW dealer check them
for compression efficiency using a calibrated
valve spring compressor.
5 The valves should be cleaned and checked
for signs of wear or burring. Where this has
occurred, the inlet valve may be reground on
a machine at a dealer. Exhaust valves must
not be reground on the machine but ground in
by hand. On engines fitted with hydraulic
tappets, valves should not be re-cut as this
will adversely affect the operation of the
tappets.
6 Wear in the valve guides may be detected
by fitting a new valve in the guide and
checking the amount that the rim of the valve
will move sideways when the top of the valve
stem is flush with the top of the valve guide.
The valve rock limits are given in the
Specifications. New valve guides must be
fitted and reamed by your VW dealer.
7 Do not spend too long grinding in the
valves. If the valve seat and valve are not
satisfactory after 15 minutes then you will
probably do more harm than good by going
on. Make sure both surfaces are clean, smear
grinding paste onto the valve evenly and using
a suction cup, work the valve with an
oscillating motion lifting the valve away from
the seat occasionally to stop ridging. Clean
the seat and valve frequently and carry on
until there is an even grey band on both seat
and valve then wipe off all the paste.
8 The surface of the head must be checked
with a straight-edge and feeler blade. Place
the straight-edge along the centre of the
machined face of the head. Make sure there
are no ridges at the extreme ends and
measure the clearance with feelers between
each combustion chamber head. This is the
area where the narrowest part of the cylinder
head gasket comes and where the gasket is
most likely to fail. If the straight-edge is firmly
in place and feelers in excess of 0.1 mm can
be put between the head and the
straight-edge, then the head should be taken
to a dealer for servicing or replacement.
9 If the cylinder head shows signs of
cracking, have it inspected by your VW dealer
to assess its condition for reuse.
10 VW recommend that the valve stem oil
seals should always be renewed to prevent
possible high oil consumption. Pulling off the
old seal is simple with pliers. With a packet of
new oil seals is a small plastic sleeve. This is
fitted over the valve stem and lubricated. The
seal should then be pushed over the plastic
sleeve until it seats on the guide. This should
be done with VW tool 10 204 which fits snugly
round the outside of the seal and pushes it on
squarely. If the seal is assembled without the
plastic sleeve, it will be damaged and oil
consumption will become excessive.
11 Before reassembling the cylinder head,
check the condition of the camshaft.
12 When all components have been
examined, then assembly of the head may
commence. Insert the valve in the correct
guide, fit the inner seat, valve springs and
outer cap, assemble the valve spring
compressor and possibly the small tube and
compress the valve spring until the collets
may be assembled to the valve stem (see
illustrations).
13 Assemble the second collet and holding
them carefully together in place, ease off the
compressor until the spring seats the collets
home. Remove the compressor, put a rag
over the valve stem and tap the stem with a
hammer. This is to ensure that the collets are
seated correctly. If they are they will not come
out. Repeat until all eight valves are in position
in the cylinder head.
14 Refit the tappets in the bores from which
they came, lubricating them liberally with
clean engine oil (see illustration). Lubricate
the camshaft bearing surfaces with oil and fit
the camshaft, positioned so that No 1 cylinder
cams point upwards.
15 Fit a new oil seal at the sprocket end,
lubricate the bearings, set the shaft in position
and install bearing caps Nos 2 and 4,
tightening the nuts in a diagonal pattern until
the shaft is in place (see illustration). Now
install the other bearing caps, making sure
they are the right way round (marks towards
the drive pulley) and tighten the caps down
using a diagonal pattern to the specified
torque. Install a new rubber seal at the
opposite end to the sprocket.
16 On engines equipped with shim bucket
tappets, adjust the valve clearances.
13 Sump and oil pump - removal
and refitting
3
Modification: From August 1985, a larger
sump is fitted thereby increasing engine oil
capacity. If renewing the sump, ensure that
one of identical capacity is fitted
Removal
12.14 Fit the tappet buckets
12.15 Fit the bearing caps
1081 VW Golf & Jetta
1 If the engine is in the vehicle then drain the
engine oil. Note that the sump plug has an
O-ring which must be renewed (see
illustration).
2 Undo the sump retaining bolts and remove
the sump from the lower face of the
crankcase. Remove the sump gasket which
must also be renewed.
3 To remove the oil pump, undo the two
retaining bolts and lower the pump unit,
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•13
13.1 Sump, oil pump and oil filter
components - fuel injection engine
2C
complete with the oil pick-up pipe and
strainer.
Refitting
4 To refit the pump, ensure that the mating
faces are clean, locate it in position and fit and
tighten the securing bolts to the specified
torque.
5 Locate the new sump gasket but do not
apply an adhesive sealant. Refit the sump and
tighten the retaining bolts evenly to the
specified torque.
6 Refit the oil drain plug with O-ring and
tighten it to the specified torque.
14 Pistons and connecting rods
- removal
3
1 Remove the cylinder head.
2 Remove the sump.
3 Unscrew the two oil pump retaining bolts
then lower and remove the pump, complete
with oil pick-up pipe from the crankcase.
Place it on one side for cleaning and
inspection.
4 The piston and connecting rod removal
procedure now follows that given for the smaller
engine variants in Part A of this Chapter.
1081 VW Golf & Jetta
15 Crankshaft and main
bearings - removal
3
1 Disconnect the pistons and connecting
rods from the crankshaft. Note that, although
the engine has to be removed to remove the
crankshaft, the cylinder head, pistons and
connecting rods can be left in position.
2 At the flywheel end, undo and remove the
six bolts securing the oil seal flange to the
crankcase (see illustration). Withdraw the
flange, seal and gasket.
3 Examine the main bearing caps. It will be
2C•14 Engine repair procedures - 1.6 and 1.8 litre 8 valve
15.2 Crankshaft and cylinder block components
seen that the caps are numbered 1 to 5 and
that the number is on the side of the engine
opposite the oil pump position. Identify these
numbers. If they are obscured, then mark the
caps in the same way as the connecting rod
caps. Before removing the caps, push the
crankshaft to the rear and check the endfloat
using a feeler blade between the thrustwasher
flanges on No 3 main bearing and the
crankshaft web (see illustration). It must not
exceed the specified maximum.
4 Remove the bearing cap retaining bolts,
remove the bearing caps and lift out the
thrustwashers from each side of the centre
main bearing.
5 Lift out the crankshaft and then remove the
top half bearing shells. If the main bearings
are not being renewed, make sure the shells
are identified so that they go back into the
same bearing cap the same way round
15.3 Checking crankshaft endfloat at
No. 3 main bearing
16.5a Intermediate shaft retaining flange
bolts (arrowed)
16 Intermediate shaft - removal
3
1 The intermediate shaft can only be
withdrawn from the crankcase with the engine
removed from the vehicle.
2 Remove the timing belt.
1081 VW Golf & Jetta
3 Remove the fuel pump on carburettor
models and the ignition distributor.
4 Before removing the intermediate shaft,
check that the endfloat does not exceed the
maximum specified amount.
5 Undo the two sealing flange retaining bolts
then withdraw the intermediate shaft,
complete
with
sealing
flange
(see
illustrations).
6 Withdraw the sealing flange from the
intermediate shaft. The oil seal within the
flange and the O-ring must be renewed on
reassembly.
16.5b Withdrawing intermediate shaft
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•15
17 Oil filter - renewal
1
Refer to Chapter 1, Section 18
18 Oil cooler - removal and
refitting
2
1 On fuel injection models, an oil cooler is
fitted between the oil filter cartridge and
mounting bracket. The cooler must be
renewed if the engine oil has been
contaminated with metal particles, such as
might be the case following total or partial
engine seizure. Renew it anyway if it is likely
to contain any other harmful contaminant.
2 To remove the cooler, first remove the oil
filter cartridge.
3 Drain the cooling system and disconnect
the coolant hoses from the cooler.
4 Remove the cooler retaining nut and the
cooler. The O-ring between the cooler and
mounting must be renewed.
5 Refitting is a reversal of the removal
procedure. Wipe clean the sealing faces of the
cooler and mounting and smear the O-ring
with clean engine oil.
6 On completion, top-up the engine oil and
coolant levels. Start the engine and check for
any signs of leaks.
19 Oil filter mounting - removal
and refitting
2
1 Remove the oil filter and on fuel injection
models, the oil cooler.
2 Disconnect the oil pressure switch lead,
undo the oil filter mounting securing bolts and
withdraw the mounting and gasket.
3 The oil pressure switch can be unscrewed
from the top face of the mounting if required.
Renew the switch O-ring.
4 Refitting is a reversal of the removal
procedure. Renew the mounting gasket.
20 Oil seals - renewal
2 Carefully prise out the oil seal with a
screwdriver or strong wire and wipe clean the
recess (see illustration).
3 Fill the space between the lips of the new
seal with multi-purpose grease, then drive it
squarely into the housing using a block of
wood or suitable metal tubing. If at all
possible, use VW fitting sleeve No. 2003 to
avoid damage to the oil seal lip.
4 Refit the driveplate or clutch.
Timing belt end
5 Remove the alternator, together with its
drivebelt.
6 Remove the timing belt cover and timing
belt, ensuring that the timing marks are
correctly aligned.
7 Unscrew the bolt from the front of the
crankshaft, withdraw the pulley and sprocket
and remove the Woodruff key. On manual
gearbox models, if the belt is difficult to
loosen, have an assistant engage top gear
and apply the brakes. On automatic
transmission models, remove the starter
model and restrain the driveplate ring gear
with a suitable lever.
8 Prise out the oil seal or extract it with VW
tool No. 2085, then wipe clean the recess
(see illustration).
9 Fill the space between the lips of the new
seal with multi-purpose grease, then drive it
squarely into the housing using a block of
wood or suitable metal tubing. If available use
VW fitting sleeve No. 3083.
10 The remaining refitting procedure is a
reversal of removal. Ensure that the timing
marks are aligned before refitting the timing
belt and tensioning it.
extract it with VW tool No. 2085, then wipe
clean the recess.
15 Fill the space between the lips of the new
seal with multi-purpose grease, then drive it
squarely into the cylinder head using a block
of wood or suitable metal tubing. If available,
use VW fitting sleeve No. 10-203.
16 The remaining refitting procedure is a
reversal of removal. Ensure that the timing
marks are aligned before refitting the timing
belt and tensioning it.
Camshaft front seal
Intermediate shaft seal
11 Remove the alternator together with its
drivebelt.
12 Remove the timing belt cover and timing
belt, ensuring that the timing marks are
correctly aligned.
13 Hold the camshaft sprocket stationary
with a screwdriver inserted through one of its
holes, then unscrew the bolt and remove the
washer, sprocket and Woodruff key.
14 Prise out the oil seal or alternatively,
17 Remove the alternator together with its
drivebelt.
18 Remove the timing belt cover and timing
belt, ensuring that the timing marks are
correctly aligned.
19 Hold the intermediate shaft sprocket
stationary with a screwdriver inserted through
one of its holes, then unscrew the bolt and
remove the washer, sprocket and Woodruff
key.
20 Renew the oil seal.
21 The remaining refitting procedure is a
reversal of removal. Ensure that the timing
marks are aligned before refitting the timing
belt and tensioning it.
4
20.2 Flywheel end crankshaft oil seal
components
1 Intermediate plate
2 Bolt
3 Oil seal
4 Sealing ring (not
fitted to all models)
21 Examination and renovation
- general information
Note: The following procedures were all
carried out with the engine in the vehicle
Crankshaft seals
Refer to Section 20 in Part A of this Chapter.
Flywheel/driveplate end
1 On manual gearbox models, remove the
clutch and pressure plate. On automatic
transmission
models,
remove
the
transmission then unbolt the driveplate from
the crankshaft, noting the location of the
spacer and shim(s).
22 Crankshaft and bearings examination and renovation
20.8 VW tool 2085 for removing crankshaft
oil seal (timing belt end) and
camshaft oil seal
1081 VW Golf & Jetta
5
Refer to Section 21 in Part A of this Chapter.
2C
2C•16 Engine repair procedures - 1.6 and 1.8 litre 8 valve
25.2 Examine face of oil pump cover for
scoring
23 Cylinder block/crankcase examination and renovation
5
Refer to Section 22 in Part A of this Chapter.
24 Pistons and connecting rods
- examination and renovation
4
Refer to Section 23 in Part A of this Chapter.
25 Oil pump - examination and
renovation
3
1 With the oil pump on the bench, prise off
the cap with a screwdriver and clean the
strainer gauze in fuel. Refit the gauge and
press on the cap.
2 Remove the two small bolts and take the
cover away from the body. Examine the face
of the cover (see illustration). As seen in the
25.3 Checking oil pump gear backlash
illustration, the gears have marked the cover.
If the depth of this marking is significant, then
the face of the cover must be machined flat
again.
3 Remove the gears and wash them with the
body in clean paraffin. Dry and reassemble
the gears, lubricating them with clean engine
oil. Measure the backlash between the gears
with a feeler blade (see illustration). This
should be 0.05 to 0.20 mm.
4 Now place a straight-edge over the pump
body along the line joining the centre of the
two gears and measure with a feeler blade the
axial clearance between the gears and the
straight-edge (see illustration). This must not
exceed 0.15 mm.
5 If all is well, check that the shaft is not slack
in its bearings and reassemble the pump for
fitting to the engine.
6 If there is any doubt about the pump, it is
recommended that a replacement be
obtained. Once wear starts in a pump it
progresses rapidly. In view of the engine
damage that may follow a loss of oil pressure,
skimping the oil pump repair is a false
economy.
25.4 Checking oil pump gear endfloat
26 Intermediate shaft examination and renovation
1 Check the fit of the intermediate shaft in its
bearing. If there is excessive play, the shaft
must be compared with a new one. If the shaft
is in good order but the bearings in the block
are worn, then seek expert advice.
2 Check the surface of the cam which drives
the fuel pump (where applicable). If serious
ridging is present, a new shaft is indicated.
3 Check the teeth of the distributor drivegear
for scuffing or chipping. Check the condition
of the timing belt sprocket.
4 It is unlikely that damage to the shaft has
happened but if it has, seek advice from a VW
dealer.
5 There is an oil seal in the flange for the
intermediate shaft. This may need renewal if
there are signs of leakage. To do this, remove
the timing belt sprocket and withdraw the
flange from the shaft. The oil seal may now be
prised out and a new one pressed in. Always
fit a new O-ring on the flange before
assembling it to the cylinder block.
27 Flywheel/driveplate examination and renovation
27.3 Flywheel/driveplate ignition timing marks
Engine code EZ (1.6)-flywheel a = 37.0 mm 18° BTDC
Engine code EZ (1.6)-driveplate: a = 42.0 mm 18° BTDC
Engine code EV (1.8) - flywheel: a = 12.5 mm 6° BTDC
Engine code GU (1.8) - flywheel a = 37.0 mm 18° BTDC
Engine code GU (1.8) - driveplate: a = 42.0 mm 18° BTDC
1081 VW Golf & Jetta
5
4
1 Inspect the starter ring teeth. If these are
chipped or worn then renew the starter ring.
This means heating the ring until it may be
withdrawn from the flywheel, or alternatively,
splitting it. A new one must then be shrunk on.
If you know how to do this and you can get a
new ring then the job can be done but it is
beyond the capacity of most owners.
2 Serious scoring on the flywheel clutch
facing requires a new flywheel. Do not
attempt to clean the scoring off with a scraper
or emery. The face must be machined.
3 If it is necessary to fit a new flywheel, the
ignition timing mark must be made by the
owner. The new flywheel has only the TDC
mark as an O on the outer face. Punch or
scribe the appropriate timing mark for your
model to the left of the TDC mark at the
appropriate distance (see illustration).
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•17
30.3a Fitting flanged type centre main
bearing into crankcase
30.3b Fitting alternative type centre main
bearing into crankcase . . .
30.3c . . . together with thrustwashers
30.3d Fitting flanged type centre main
bearing to cap
30.3e Fitting centre bearing and separate
thrustwashers to cap
30.3f Ensure that ends of bearing are flush
with joint face
4 On automatic transmission models, check
the driveplate as described for the flywheel. It
will also be necessary to mark a new
driveplate for ignition timing.
aperture in the rear end of the crankshaft. It
may already have been removed by the
supplier, but check anyway.
2 Clean the crankcase recesses and bearing
caps thoroughly and fit the bearing shells so
that the tang on the bearing engages in the
recess in the crankcase or bearing cap.
Ensure that the shells fitted to the crankcase
have oil grooves and holes and that these
align with the drillings in the bearing housings.
When fitting the bearing shells to the caps,
note that bearing Nos. 1, 2 and 5 are plain
shells whilst No. 4 has an oil groove.
3 The bearing shells of the centre bearing
(No. 3) may either be flanged to act as
thrustwashers, or may have separate
thrustwashers. These should be fitted oil
groove outwards. Fit the bearing shells so that
the ends of the bearing are flush with the joint
face (see illustrations).
4 Oil the bearings and journals then locate
the crankshaft in the crankcase.
5 Fit the main bearing caps (with centre main
bearing thrustwashers if applicable) in their
correct positions (see illustration).
6 Fit the bolts to the bearing caps and tighten
the bolts of the centre cap to the specified
torque, then check that the crankshaft rotates
freely.
7 Working out from the centre, tighten the
remaining bearing caps in turn, checking that
the crankshaft rotates freely after each
bearing has been tightened.
8 Check that the endfloat of the crankshaft is
within specifications by inserting feeler blades
between the crankshaft and the centre
bearing thrust face/washer while levering the
crankshaft first in one direction and then in the
other.
9 Lubricate the rear of the crankshaft and
using a new gasket, install the rear oil seal and
flange. Tighten the six bolts (see illustration).
30.5 Fitting main bearing caps
30.9 Fitting crankshaft rear oil seal and
flange
28 Timing belt and sprockets examination and renovation
1
Refer to Section 26 in Part A of this
Chapter. The information given also applies to
the intermediate shaft sprocket.
29 Engine reassembly - general
information
Refer to Section 28 in Part A of this Chapter.
30 Crankshaft and main
bearings - refitting
3
Note: If it is difficult to rotate the crankshaft,
check that the bearing shells are seated
properly and that the bearing cap is in the
correct way round. Rotation will only be difficult
if something is incorrect and the fault must be
found. Dirt on the back of a bearing shell is
sometimes the cause of a tight main bearing.
1 If a new crankshaft is being fitted to
automatic transmission models, the needle
roller bearing supplied and fitted by the
manufacturer will need to be removed from its
1081 VW Golf & Jetta
2C
2C•18 Engine repair procedures - 1.6 and 1.8 litre 8 valve
10 Lubricate the front of the crankshaft and
fit the front oil seal and flange with a new
gasket. Tighten the bolts to the correct
torque.
31 Intermediate shaft - refitting
3
Lubricate the intermediate shaft with clean
engine oil then install it in the block.
Fit the O-ring and flange, together with the
oil seal, then tighten the bolts. Note that the
oil hole must be at the bottom of the flange.
32 Pistons and connecting rods
- refitting
3
Proceed as described in Section 30, Part A
of this Chapter, paragraphs 2 to 7 inclusive.
When refitting the big-end nuts, oil the
threads.
On completion, check the endfloat of each
connecting rod in a similar manner to that
described for checking the crankshaft
endfloat.
33 Valve clearances - checking
and adjustment (pre August
1985)
3
1 If a new or reconditioned cylinder head,
complete with camshaft, is being fitted, then
the valve clearances will have been preset.
2 Valve clearances can be checked and
adjusted with the cylinder head removed
(prior to refitting after overhaul) or in the
normal manner described in Section 12 of
Chapter 1.
3 There are two specified valve clearance
settings, these being for a cold (cylinder head
removed) or warm (engine in vehicle) engine
condition.
4 If valve adjustment is made with the engine
cold, then it must be checked again with the
engine at normal operating temperature (ie.
coolant above 35°C). If the cylinder head has
been overhauled, then it should be checked
again, hot, after 600 miles (900 km).
34 Cylinder head - refitting
34.2 Cylinder head gasket located on
block
34.3a Lowering cylinder head onto block
Using this as a datum, install a new cylinder
head gasket so that the word ‘OBEN’ on the
gasket is over this datum point and on the top
side of the gasket (see illustration).
3 Lower the cylinder head into position,
locating onto the centring pins where fitted
(see illustration). If the cylinder block does
not have centring pins, initially refit new No. 8
and No. 10 cylinder head bolts. Do not use
jointing compound. Check that the gasket is
seating correctly and fit the remainder of the
new bolts. Following the sequence shown,
tighten the bolts until the head is firmly held.
Using a torque wrench, tighten the bolts in
stages to the specified torque following the
same sequence (see illustration).
4 The cylinder head will not need further
tightening.
refit the timing belt sprocket onto the shaft.
Lubricate the retaining bolt with oil, locate the
spacer washer onto the bolt then fit and
tighten it to the specified torque wrench
setting. When tightening the bolt, prevent the
crankshaft from turning by using the same
method as that for its removal.
3 Locate the Woodruff key into its groove on
the front of the camshaft then refit the
camshaft sprocket. Refit the retaining bolt
together with the spacer washer and tighten
to the specified torque wrench setting. Hold
the sprocket stationary when tightening by
inserting a screwdriver through one of its
holes and jamming it against the cylinder
block or head.
4 If removed, refit the timing belt rear cover.
Apply locking compound to the stud thread.
5 Locate the crankshaft pulley onto the
sprocket (aligning the marks made previously)
using one bolt to secure it temporarily.
6 Turn the camshaft sprocket so that the
lobes of No. 1 cylinder cams are pointing
upwards and the mark on the camshaft
sprocket is aligned with the valve cover - see
illustration 9.7a.
7 Rotate the crankshaft sprocket and the
intermediate shaft sprocket until the dot on
the intermediate sprocket and the mark on the
V-belt pulley coincide. Install the timing belt
tensioner loosely and then the timing belt.
Making sure the marks are still in place, put a
spanner on the adjuster and tighten the belt
until it will twist only 90 degrees when held
between the finger and thumb halfway
35 Timing belt and sprockets refitting
3
1 Fit the Woodruff key into its groove in the
intermediate shaft then refit the sprocket to
the front of the shaft. Locate the spacer
washer onto the bolt then fit and tighten the
bolt to the specified torque wrench setting.
Hold the sprocket stationary when tightening
by inserting a screwdriver through one of its
holes and jamming it against the cylinder
block.
2 Locate the Woodruff key (if applicable) to
the groove at the front of the crankshaft then
3
Note: New cylinder head retaining bolts must
be used on refitting
1 Clean the top face of the block. Clean and
inspect the bores and lubricate them with
clean engine oil. Turn the crankshaft so that
the pistons are in the mid-cylinder position.
2 The engine number is stamped on an
inclined surface between No. 3 and No. 4
cylinders on the side above the distributor.
34.3b Cylinder head bolt tightening sequence
1081 VW Golf & Jetta
Engine repair procedures - 1.6 and 1.8 litre 8 valve 2C•19
between the camshaft and intermediate shaft
sprockets. Tighten the eccentric adjuster nut
to the specified torque - see illustration 9.8.
8 Unbolt and remove the crankshaft V-belt
pulley.
9 Fit the lower timing cover then refit the
crankshaft V-belt pulley and tighten its
retaining bolts to the specified torque.
10 Locate the new valve cover gasket on the
cylinder head, the seal to the No. 1 camshaft
bearing cap and the half round grommet into
its location at the rear end of the cylinder
head.
11 Fit the valve cover into position, locate the
reinforcement strips then refit and tighten the
retaining nuts evenly to the specified torque.
12 Refit the upper timing belt cover.
36 Engine ancillary components
- refitting
3
1 On automatic transmission models, refit the
driveplate together with any shims originally
located between the crankshaft and the plate.
Fit the washer on the transmission side of the
driveplate, ensuring that the chamfered side
of the washer faces towards the driveplate.
Use new bolts and tighten them to the
specified torque setting then using vernier
calipers, check the distance between the
driveplate and the cylinder block as shown
(see illustration) at three positions. If the
clearance is not between 30.5 and 32.1 mm,
remove the driveplate, fit shims of suitable
thickness between the driveplate and the
crankshaft, then refit the driveplate assembly
and recheck the clearance. If the engine is a
new or reconditioned short block replacement, check that the bore in the rear end does
not contain a needle roller bearing. If it does,
then remove the bearing as this is for manual
gearbox models only.
2 On manual gearbox models, refit the clutch
together with the intermediate plate.
3 Refit the inlet and exhaust manifolds.
4 Refit the coolant pump and all hoses to the
engine.
5 Refit the alternator and drivebelt.
6 Refit the oil pressure switch to the cylinder
head or filter mounting as applicable, using a
new washer or O-ring. Tighten to the specified
torque.
7 Fit the oil filter mounting to the cylinder
block, together with a new gasket and tighten
the bolts. On models fitted with an oil cooler,
refit the supply and return hoses to their
correct unions.
8 Fit the oil filter.
9 Refit the distributor.
10 On carburettor models, refit the fuel
pump.
11 On fuel injection models, refit the
warm-up valve (if the hoses were
disconnected) .
12 Refit the coolant temperature sender unit
and the thermotime switch with new O-rings.
13 Refit the spark plugs, if not already done.
14 Refit the gearbox/transmission to the
engine.
37 Engine - refitting
4
To refit the engine/transmission, reverse the
removal procedures but note the following:
a) When lowering the unit into the engine
compartment, align the driveshafts with
the flanges prior to attaching the
respective mountings
b) Assemble the engine mountings loosely
initially and tighten them only after the
unit is central without straining the
mountings
c) Adjust the clutch cable (manual gearbox)
d) Adjust the throttle and selector cables
(automatic transmission)
e) Reconnect and adjust the gear selector
linkages (manual gearbox)
f) Adjust the throttle and choke cables
g) Refill the cooling system
h) Refill the engine with the correct grade
and quantity of oil
i) Where necessary, retension the power
steering pump drivebelt and replenish the
system fluid
38 Hydraulic bucket tappets checking free travel (from
August 1985)
3 Irregular noises are normal when starting
but should become quiet after a few minutes
running.
4 If the valves are still noisy, carry out the
following check to identify worn tappets.
5 Stop the engine and remove the valve cover
from the cylinder head.
6 Turn the crankshaft clockwise by using a
wrench on the crankshaft pulley securing bolt,
until the cam of the tappet to be checked is
facing upward and is not exerting any
pressure on the tappet.
7 Press the tappet down using a wooden or
plastic wedge.
8 If free travel of the tappet exceeds that
specified, the tappet must be renewed.
39 Engine - adjustments after
major overhaul
Refer to Section 41 in Part A of this Chapter.
If new hydraulic bucket tappets have been
fitted, it is essential that no attempt to restart
the engine is made for a minimum period of
30 minutes after installation. Failure to
observe this precaution may result in engine
damage caused by the valves contacting the
pistons.
2
1 Start the engine and run it until the radiator
cooling fan has switched on once.
2 Increase engine speed to about 2500 rpm
for about two minutes.
36.1 Checking driveplate-to-cylinder block dimension (A) using vernier calipers
1081 VW Golf & Jetta
2
2C
2C•20
Notes
1081 VW Golf & Jetta